A spot welding machine is often referred to as a thermal welders. The welding machine is used in a welding environment to weld several thin sheet metals together by means of a torch. This process is done by injecting a wire feed into a welder and feeding the torch in the opposite direction to create an arc. The torch that is used for spot welding can range from one to four; more than four will require additional welders to be available for the job. The welder that we use in this process has a small piece of metal called a ‘welding rod’ at the tip that is specifically for welding.
There are a few different ways that a spot welding machine works. In the first it will begin with a welder guiding the torch in the direction of where the desired welding areas are located. Once the weld is created and the weld is complete, we must place the welding rods and electrodes in the correct location. electrode holes are drilled into the metal being joined together before the electrodes are pushed into place and a clamping clamp is used to hold the electrode in position. As the arc is created, electricity is passed through the conductors to the weld puddle.
Once the welder has created a weld puddle, the clamps are removed and the metal sheets are pushed together and pressed into one another. This creates an air pocket between the two metals that is filled with flux – this is known as a ‘weld force’. The flux will help to hold the metal sheets in position as the weld puddle fills with flux, and this is how a spot welding machine produces strong, secure joints.
The welder then uses a tig saw and a power saw to cut the welded areas out of the sheet metal. The spot welding machine uses a variety of different methods for cutting and shaping the metal to get the proper joint configuration. Some welders use continuous hammering to quickly and accurately create a weld line. Others use a rotating hammer and a cutting torch to rapidly and accurately create a weld line. The type of cutting that is done will depend on what type of part the welder is working on and how much metal needs to be produced in the fastest and most efficient way.
A very common method that is used for spot welding is called ‘continuous cutting’ or ‘continuous hammering’. In this process, the welder uses the same welder arc to continuously hit the welding area and the welder does not need to turn the power supply on and off, enabling them to work continuously and weld without interruptions. In some applications and designs, however, the welder may need to turn the power supply on and off periodically, especially if the welder is using a larger torch than what is on hand in their shop. The reason for this is because the power supply will need to regulate the temperature that the torch is operating at and a fluctuation in this temperature can cause a catastrophic fire. In these cases, it is often better to operate the torch with a smaller torch until you have learned how to operate a continuous cutting and hammering power supply.
If your project calls for fast production and consistent results, a power supply with both constant and oscillating voltage is needed. Oscillating volts are required for spot welding operations that require the welder to continuously strike a metal with each exposure to the filler wire. This method of power supply is often more costly because of the constant voltage requirements. Constant voltage operations are also more stable because they do not require the welder to turn on the power supply during the process of the welding operation. This is especially true in the case of metal fabrication where the welder often needs to go back and forth with their welding efforts to continue fabrication.